Flexible pouch and method of forming a flexible pouch

ABSTRACT

A method of forming and filling the pouch includes the steps of forming each panel and joining two panels by sealing together the side edges and lower edge. The method also includes the steps of opening the pouch and filling the pouch with the product. The method further includes the steps of closing the filled pouch by forming a first closing seal extending along an upper edge of the pouch a predetermined length from the upper edge, such that there is no dead space inside the pouch between the product and the first closing seal, and forming a second seal between the first closing seal and the upper edge thereby trapping the product between the first closing seal and the second closing seal, and finishing the pouch.

RELATED APPLICATION

This application is a Divisional of U.S. patent application Ser. No.10/533,615 filed Apr. 29, 2005, which is the National Phase ofPCT/US2003/034396 filed Oct. 30, 2003, which claims priority of U.S.Provisional Patent Application Ser. No. 60/422,282 filed Oct. 30, 2002,which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to flexible pouches forpackaging a product and, more specifically, to a flexible pouch forpackaging a product and a method of manufacturing the same.

2. Description of the Related Art

Various types of disposable, portable containers are known in the artfor storing a fluid or dry product, such as a liquid, granular material,powder or the like. One example of such a container is a flexible pouch.Consumers prefer the convenience of flexible pouches, due to theirshape, size and shelf life. Manufacturers recognize the packagingbenefits of a flexible pouch, since the pouch can be formed and filledon the same manufacturing line. An example of a method and apparatus forfilling a flexible pouch with a product is disclosed in commonlyassigned U.S. Pat. No. 6,199,601, which is incorporated herein byreference.

The flexible pouch is made from a flexible material, preferably alaminate composed of sheets of plastic or aluminum or the like. In thisexample, the material is available in sheet form, on a roll. An outerlayer of the material may include preprinted information, such as alogo, or the like, to provide the consumer with information regardingthe contents of the pouch. The pouch may be formed using conventionallyknown manufacturing techniques, such as a horizontal form-fill sealmachine, a flat bed pre-made pouch machine, a vertical form-fillmachine, or the like. The pouch is generally formed by folding sheets ofmaterial over each other to achieve a predetermined shape. Edges, suchas a side edge, are joined together using a sealing technique such asbonding or welding. Alternatively, the pouch is formed by laying onelayer of material over a second layer of material and forming a gussetalong two parallel edges to form a pouch capable of standingunsupported. An upper edge of the front panel and back panel isgenerally not sealed until after the pouch is filled. The empty pouchmay be placed in a holder such as a cup or puck prior to the fillingprocess. To fill the pouch, the upper edges of the pouch are spreadapart. For example, a concentrated flow of gas is directed towards theupper edge of the pouch to separate the panels. Grippers may also beutilized at the same time to pull the panels apart. The pouch is filled,sealed and finished.

Flexible pouches have been used for some time to distributenon-carbonated beverages, such as fruit juice and the like. However,their use with carbonated beverages has been limited since the presentlyavailable materials are somewhat permeable, thereby allowing loss of theinternal carbon dioxide gas from the pouch and its replacement withoxygen. The presence of oxygen in the filled pouch increases the chanceof bacteria forming, or may affect the taste. Thus, there is a need inthe art for a flexible pouch that can be used to distribute carbonatedbeverages and a method of making such a pouch.

SUMMARY OF THE INVENTION

Accordingly, the present invention is an improved flexible pouch for aproduct and an improved method for manufacturing and filling the pouch.The flexible pouch includes a front panel and a back panel each havingan upper edge, a lower edge opposite the upper edge, and side edgesextending therebetween the upper and lower edges. The pouch includes afirst closing seal extending along an upper edge of the joined front andback panel formed a predetermined length from the open edge so thatthere is no dead space inside the pouch between the product and thefirst closing seal and a second closing seal outside the first closingseal, to form a pocket trapping some of the product between the firstclosing seal and the second closing seal.

The method includes the steps of forming each panel and joining twopanels by sealing together the side edges and lower edge. The methodalso includes the steps of opening the pouch and filling the pouch withthe product. The method further includes the steps of closing the filledpouch by forming a first closing seal extending along an upper edge ofthe pouch a predetermined length from the upper edge, such that there isno dead space inside the pouch between the product and the first closingseal, and forming a second seal between the first closing seal and theupper edge thereby trapping the product between the first closing sealand the second closing seal, and finishing the pouch

One advantage of the present invention is that a flexible pouch andmethod of making a flexible pouch filled with a carbonated beverage isprovided. Another advantage of the present invention is that a flexiblepouch and method of making a flexible pouch filled with a carbonatedbeverage is provided that utilizes a laminate material which includesPET foil cast polypropylene. Still another advantage of the presentinvention is that the method of making a flexible pouch filled with acarbonated beverage includes seams that are heat sealed in a two-stepprocess to eliminate gas, such as oxygen, in the head space of thepouch. A further advantage of the present invention is that a method ofmaking a flexible pouch is provided that utilizes a low heat and a highheat weld to weld the seams. A still further advantage of the presentinvention is a flexible pouch and a method of making a flexible pouchfilled with a carbonated beverage is provided that is cost-effective tomanufacture. Yet a further advantage of the present invention is thatthe flexible pouch retains its shape as the product is removed.

Other features and advantages of the present invention will be readilyappreciated, as the same becomes better understood after reading thesubsequent description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of a flexible pouch, according to thepresent invention.

FIG. 2 is a flowchart of a method of forming and filling a flexiblepouch, according to the present invention.

FIG. 3 is a block diagram of an apparatus for forming and filling aflexible pouch using the method of claim 2.

FIG. 4 is an elevational view of a pouch prior to filling, according tothe present invention.

FIG. 5 is an elevational view of a pouch after sealing, according to thepresent invention.

FIG. 6 is an elevational view of the pouch with a fitment for a straw,according to the present invention.

FIGS. 7 a and 7 b are elevational views of pouches with spout fitments,according to the present invention.

FIG. 8 is an elevated view of a flexible pouch illustrating the materiallayers, according to the present invention.

FIG. 9 is a perspective view of a filled flexible pouch, according tothe present invention.

FIG. 10 is a schematic top view of a rotary fill machine according tothe present invention.

FIG. 11 is a cup carrying receptacle for use with the machine shown inFIGS. 10 and 12, according to the present invention.

FIG. 12 is a servo feed device according to the present invention.

FIG. 13 is a schematic top view of a continuous fill machine inaccordance with the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring to FIGS. 1-9, a sealed, flexible pouch 10 is illustrated. Thepouch 10 is filled with a product (not shown) and sealed. In thisexample, it is contemplated that the product is a fluid which iscarbonated, or one to which carbonation is added, such as juice, soda,an alcoholic beverage or the like. The pouch may contain a singleserving of a product, or multiple servings. It is contemplated that thepouch illustrated in FIG. 1 contains a tear-off portion formed at thetop for accessing the product contained therein. Alternatively, afitment such as a removable and replaceable cap is mounted to the topportion or side portion of the pouch, as shown in FIGS. 7 a and 7 bthrough 9.

The pouch 10 is constructed by a front panel 12 and a back panel 14 thatare joined together in a manner to be described, to form a pouch 10. Inthis example, each panel 10 has a generally rectangular shape, althoughother shapes are contemplated. Further, the panel is defined by an upperedge 16, an opposed lower edge 18, and side edges 20 extendingtherebetween the upper and lower edges 16, 18. The pouch 10 may includea sidewall 22 disposed between the side edges 20, the lower edge 18, orboth the side and lower edges which allows the pouch 10 to standupright. For example, the sidewall 22 may include a gusset formed in thesidewalls, which is generally wider at the lower edge and tapersupwardly towards the upper edge. Alternatively, the gusset may be formedbetween the lower edges to form a base for the pouch 10 to stand.

The flexible pouch 10 may advantageously includes a guide pocket 24formed in a panel 14, 16 or wall of the pouch 10 prior to filling andsealing, to facilitate the separation of the front and back panels 14,16 prior to the filling of the pouch 10. An example of such a pouch isdisclosed in commonly assigned U.S. patent application Ser. No.10/310,221.

The flexible pouch 10 is formed of laminate sheets as shown in FIG. 8,which provide a barrier against oxygen penetration and retains carbondioxide within the pouch. In one embodiment, the laminate includes atleast one layer 46 of virgin polyethylene terphalate (PET) and at leastone layer 48 of aluminum foil and another layer 49 such as EVOM, PET orpolyethylene. In a preferred embodiment, the laminate includes metalizedfoil paper layer 48 laminated to a cast polypropylene layer 46 andanother layer 49 of PET, polyethylene or EVOM. It should be appreciatedthat there may be a fourth layer. The choice of layer material is drivenby the product contained in the pouch 10. The laminate material may beeither a 3 or 4 gauge material. The pouch 10 is particularly suited forpackaging beer, wine or other carbonated fluids since the carbonationacts as a microbiocide and preserves the flavor and aroma of theproducts, as well as adding strength to the walls of the pouch.Advantageously, a pouch 10 made from the cast polypropylene laminatematerial retains its filled shape even as the product is removed fromthe pouch 10. Thus, the pouch can be shaped like a traditionalcylindrical can, as shown in FIG. 9.

It should be appreciated that the pouch 10 may include other componentsor features, as is known in the art. For example, the pouch 10 mayinclude a fitment 26 for dispensing the product from the pouch 10.Various types of fitments 26 are known in the art for this purpose. Itshould be appreciated that the fitments may be formed prior to fillingthe pouch. For example, the pouch 10 may include a fitment 26 forreceiving a straw, as shown at 28 in FIG. 6. Another example of afitment 26 is a spout fitment with cap, as shown at 30 in FIGS. 7 a and7 b, and 8-9. Advantageously, the style of pouch may stand up on itsown, as shown in FIG. 9. Alternatively, an upper edge 16 of the panel 14may include a weakened area, to facilitate opening the pouch 10 bytearing off an upper portion of the top, as shown in FIG. 1 at 32. Thepouch may include a resealable closing fitment 34, such as a zipper likethat sold under the name TopTite™.

Referring to FIG. 2, a method for forming and filling the flexible pouch10 using the apparatus described with respect to FIG. 3 is illustrated.The method begins in block 100 with the step of forming a pouch. Forexample, the panels 12, 14 that define the walls of the pouch 10 areformed in a panel cutting operation. The panels 12, 14 are made from apreprinted laminate of material, as previously described. The materialis a laminate of layers 46, 48, preferably three. One layer of thematerial is preferably preprinted with information or locating indicia(not shown), such as a registration mark. The registration marks arelocated on the material to denote an edge of a panel 12, 14. Theregistration marks are read by an optical reading device (not shown),such as a scanner, to index the material in a predetermined position atthe cutting station. The preprinted information may include labelinginformation that describes the product contained within the pouch. Inthis example, the layer of preprinted information is located on an outerlayer of the material. The material is removed from the roll and cutinto panels 12, 14. Each panel 12, 14 has a predetermined shape, whichin this example is a rectangle. The material is cut into a panel 12, 14using a known cutting apparatus, such as a laser or punch or the like.

Alternatively, the pouches 10 may be provided in a bandolier. In thistype of apparatus, a strip of pouches arranged bottom to top isprovided. The pouches 10 are sealed across the lower edge 18, so thatthey are sterile until a cut is made through them separating the twopouches 10 from one another and providing an opening at the top of oneof the pouches 10. The lower edge 18 of the adjacent pouch is trimmed toshape, for example the corners may be angled. The cut may be performedusing a cutter or a die cut or the like.

A crease or guide pocket 24 may be formed in a top portion of each panel12, 14 in a creasing operation in order to facilitate opening andfilling the pouch. A forming technique, such as stamping, may beutilized. Another example of a forming technique is the use of heatedtubes that thermoform a crease 24 in each panel 12, 14.

When in registration, the upper edge 16 of each panel 12, 14 ispositioned between one or more lower dies and corresponding diving upperdies. The upper die is mechanically moved first downwardly and thenupwardly to stamp the predetermined shape into the top portion of eachpanel 12, 14. An example of a method of forming a crease in a panel tofacilitate opening the pouch is disclosed in commonly assigned patentapplication Ser. No. 10/310,221, which is incorporated herein byreference. The methodology advances to block 105.

In block 105, edges of the pouch 10, such as the side edge 20 and loweredge 18, are joined together in a sealing operation. One edge is leftopen, preferably designated as the upper edge 16, in order to fill thepouch. In this example, the side and lower edges 18, 20 are joinedtogether using an ultrasonic sealing process that includes theapplication of heat and compression in a two-step heat weldingoperation. A first seal 36 is slowly tack welded with a low heat, suchas 180° F. to tack the two pieces of material together, so that steam isnot released containing volatile materials such as ketones, butyls,butanes, or the like. The material may include resins, such asorganoleptic resins which produce an undesirable taste in the product.The first seal 36 is relatively wide, such as 6 mm. After the slowlow-heat weld, a second heat seal 38 is applied to the weld along theinner edge, and adjacent the contents. The second seal 38 has a width ofapproximately 2 mm, or one-third that of the first seal 36, and isheated to a higher temperature, such as 260° to provide strength.

It should be appreciated that the small width of the second seal 38along with the relatively short heating time at approximately half ofthe preheat results in minimizing the gasses created during the process.The second heat seal 38 provides strength to retard the high pressurethat is created by the sealing process. The seals 36, 38 are immediatelycooled to stabilize the pouch 10.

It should be appreciated that this heat sealing process may be appliedto any one of the edges 16, 18. If a fitment 26 is also applied, theprocess may be modified slightly. For example, if a reclosable pouch isdesired, a reclosing means 34, such as a zipper provided by Zip Tight isapplied. This type of zipper is easily opened from the outside, however,it provides resistance to pressure on the inside, and the greater thepressure on the inside, the tighter the zipper is sealed. The fitment 26is located on the pouch 10 in a variety of locations, such as mounted ona bottom, or a top, or a side portion of the pouch. Various types offitments are contemplated, including the spout fitments illustrated inFIGS. 7 a and 7 b. The methodology advances to block 110.

In block 110, the pre-made pouch 10 is then loaded into a carrier. Inthis example, the pouch 10 is placed in a holder (not shown). An exampleof a holder is a cup-shaped member, as disclosed in commonly assignedU.S. patent application Ser. No. 10/336,601, which is incorporatedherein by reference. Alternatively, the pouch 10 may be held withgrippers (not shown) as is known in the art. The methodology advances toblock 115.

In block 115, the pouch 10 is opened in an opening operation. Varioustechniques are conventionally known in the art for opening the pouch 10.For example, the guide pocket 24 formed by the crease in the front panel12 and back panel 14 facilitate opening of the pouch. A nozzle (notshown) may be mechanically lowered into the guide pocket 24 to direct astream of compressed gas into the guide pocket 24, to force the walls ofthe pouch 10 away from each other. An example of a gas is carbon dioxideor nitrogen. The blowing station may include a manifold, with a hoodextending over the top of the edges of the pouch as known in the art.The manifold has rows of apertures (not shown) formed above the upperedges 16 of the panels 12, 14 of the pouch 10. The hood is placed overthe pouch 10 to assist in maintaining the air pressure in the pouch 10.The supply of pressurized gas is directed through the aperture to form aplurality of jets of pressurized gas or air. The jets are directeddownwardly at the diamond-shaped openings formed at the upper edges 16to assist in overcoming the surface tension of the panels 12, 14 andassist in separation of the panels 12, 14. A diving rod (not shown) maythen be used to make sure the pouch 10 is fully opened. The methodologyadvances to block 120.

In block 120, the pouch 10 is filled with the product in a fillingoperation. For example, a fill tube (not shown) is lowered into theopened pouch 10 and the product is dispensed into the open pouch 10.

If the product is naturally carbonated, such as beer or soda or thelike, the pouch is preferably filled while immersed in a nitrogen bath.If the product is not naturally carbonated, it is immersed in a carbonbath to introduce carbon dioxide into the product, such as carbonator orthe like. For example, carbon dioxide is introduced into water or juiceto provide a carbonated beverage. The product may contain a mixture ofup to two volumes of carbon dioxide. It should be appreciated that thecarbon dioxide masks any undesirable taste from the ketones releasedduring the sealing process. The carbon dioxide also increases thepressure within the product so that the walls of the pouch are rigidafter the top is sealed. The product is preferably filled at atemperature ranging from 29° F. to ambient temperature.

The methodology advances to block 125 and the oxygen is removed from thepouch. For example, the carbon dioxide in the product is released andrises to the top of the pouch and into the nitrogen bath. The presenceof carbon dioxide and nitrogen in a product, such as water, prohibitsthe growth of bacteria and the formation of mold, as well as enhancingthe flavor and aroma of the product. The methodology advances to block130.

In block 130, the upper edge 16 of the pouch is closed by applying afirst closing seal 40. In this example, the pouch is closed by sealingthe upper edges 16 together using an ultrasonic weld involving theapplication of heat and pressure. The location of the first closing seal40 is selected so that some of the product in the upper portion of thepouch 10 is trapped above the first closing seal 40, such as 1 inch fromthe top as shown in FIG. 5. It should be appreciated that the sealingprocess removes the guide pocket 24 from the panels 12, 14. Any gaspresent in the pouch 10 is relatively insoluble when cold and providesstrength to the walls, rigidity to the pouch, and may be pressurized upto four volumes of gas. The methodology advances to block 135.

In block 135, a second closing seal 42 is placed through the top of thepouch, above the first seal. It should be appreciated that the locationof the seal is selected so that some of the product in the upper portionof the pouch is trapped between the first closing seal 40 and the secondclosing seal as shown at 44. The result is that the pouch 10 is 100%product, with no gas, such as oxygen, present in the head space. Thehead space is the empty region between the product and the heat seals.The second seal may be a cosmetic seal. The methodology advances toblock 140.

In block 140, the pouch 10 is finished in a finishing operation. Theedges 16, 18, 20 of the pouch 10 are trimmed to achieve a predeterminedshape. The methodology advances to block 145, and the pouch 10 isfinished at a cooling station, where the pouch 10 is cooled using aconventionally known cooling technique. The methodology advances toblock 150.

In block 150 the finished pouch 10 is discharged from the machine.

It should be appreciated that the methodology may include other steps,such as an upstream oxygen purging station, a downstream oxygen purgingstation, or the like. In addition, a manufacturing station may performone or a plurality of operations, to enhance the efficiency of themethodology and apparatus.

Referring to FIGS. 3 and 10-13, a machine for carrying out the methoddescribed with respect to FIG. 2 is illustrated. Various styles ofmachines are contemplated for filling the pouch 10. These include aturret-type machine, or a continuous motion cup receptacle machine, oran intermittent machine. For carbonated beverages, a fill-seal machine160 is preferably used to fill stand-up pouches. As shown in FIG. 10,the machine 160 is of a turret-type having radially extending arms 162.Each arm 162 carries a predetermined number of cuplike receptacles 164.As shown in FIG. 9, the receptacles 164 have a cylindrical wallextending upwardly from a bottom, as disclosed in co-pending PatentApplication No. 60/345,230. There may be up to ten receptacles 164 oneach arm 162.

The pouches 10 are made using a novel method on a flat bed or horizontalform-fill machine. The cups are delivered to a loading station byconveyor where empty pouches are loaded into the receptacles frommagazines 166 onto a rotary turret 163, as shown in FIG. 10. The pouches10 are fully formed but the upper edges 16 of the panels 12, 14 areunsealed. Each magazine 166 or turret segment holds a supply of emptyflat pouches 10. The same number of magazines or segments are needed asthe number of receptacles 164, which will be loaded onto the arm 162 ofthe turret. The magazines are positioned side by side with thereceptacles 164 below. As shown in FIG. 10, a linear cam servo feed-indevice 168 moves to push an empty pouch 10 from the magazine 166 into areceptacle 162 positioned beneath the magazine 166. The cam 170 engagesthe top pouch. The magazines are angled so that gravity pulls thepouches 10 downwardly to the cam 170 which pushes against the bottompouch in the magazine and is rotated to slide the pouch from themagazine downwardly into the corresponding awaiting receptacle 164. Thecams 170 are mounted to a single rod 172 which is rotated to move thecams in unison. The rotary turret picks a pouch 10 horizontally from themagazine 166 and loads onto a segment which transfers the empty pouchinto the receptacle 164.

The group of receptacles 164 is then fed by the conveyor 174 sidewaysonto a radial arm 162 of the turret 163. The arms 162 are sequentiallyindexed through a number of stations. The turret 163 is rotated to movethe receptacles 164 containing the pouches 10 to an opening station 176where the flat pouches 10 are opened by a group of nozzles positionedabove the pouches 10. The pouches 10 then are moved to a checkingstation where photocells or pressure is used to make sure the poucheshave been opened, 178. The pouches 10 then move to a first fillingstation 180 where pouches could be evacuated and diving nozzles arelowered into the pouch 10 to fill the pouch 10 with beverage. In thecase of larger pouches, it may be necessary to move the pouches to asecond fill station 182 to complete the filling of the pouch. Whenfilling the pouches with beer, the beer must be filled cold at 29°. Thepouches 10 then are moved to a station 184 where any oxygen in the pouchresiding above the beverage is removed. This can be done by providing ahood or diving nozzle where oxygen is either evacuated or replaced withcarbon dioxide or nitrogen into the pouch to displace the oxygen. Adiving nozzle is used to inject the gas.

The pouches 10 are then moved to a first pouch closing station 186 wherean ultrasonic sealing apparatus pushes the upper edges 16 of the panels12, 14 together over the product and ultrasonically seals the panels 12,14 together, as previously described. The ultrasonic sealing processcauses the carbonated beverage, such as beer, to produce a small amountof foam on the top of the beverage. As shown in FIG. 5, this foam forcesexcess oxygen upwardly, the first closing seal 40 is formed across thefoam at the top of the liquid to ensure that no oxygen remains in thecontainer. The pouch is then moved to a second pouch closing station 188where a second closing seal 42 is formed above the first closing seal.The second closing seal 42 traps the risen foam between the first andsecond seals. The second closing seal 42 may be a cosmetic heat sealused to seal the top edges of the pouch together. The pouches are thenmoved to a finishing station 190. The pouches 10 may be cooled or anadditional top seal may be placed over the previous two seals.

Finally, the pouches are moved to a discharge station 192 as shown instep 8 where the receptacles 164 are moved from the arm 162 of theturret 163 outwardly onto the conveyor 174. The receptacles 164 are thenmoved by the conveyor 174 under robotic arms 194 having grippers whichare then lowered to grab the pouch 10 and lift the pouch 10 from thereceptacles 164. The receptacles 164 are then moved by the conveyor 174through a rinsing station 196 and returned to the other side of theturret for use. The pouches 10 are placed by the grippers into cartons.At this point, the filled pouch is available for refrigerateddistribution as fresh product. The filled pouch 10 may be placed ontoanother conveyor belt for additional processing, such as tunnelpasteurization for shelf stabilization. In certain instances, it may bedesirable to apply steam to sterilize the pouch 10 and to wet the innersurface of the walls to facilitate handling.

As shown in FIG. 13, the pouches 10 may be filled on a continuous motionmachine 210. The continuous motion machine has rows 212 of receptacles164 mounted to a conveyor which are moved in an elliptical path past thesame stations as set forth for the rotary machine above. Up to tenreceptacles may extend across a row. Preformed pouches are fed frommagazines located above the receptacles.

The various operations such as opening, checking, filling and sealingare performed by apparatus which move over the receptacles at the samespeed as the receptacles. Two sets of identical equipment such asopening equipment are utilized. The first set travels with the beltperforming the operation while a second set is lifted upwardly by achain along a frame and then moved rearwardly and down to the startposition where it meets the next row of receptacles. The pouches areloaded into the receptacles and then moved to the start of the openingstation 214 where blowers are moved down and travel with the poucheswhile the alternate set of blowers are moved upwardly and rearwardly. Atthe end of the travel through the opening station, the pouches are fullyopened by diving wands 216. The pouches are then turned 180° to travelback down through the apparatus where they are moved sequentiallythrough an evacuation station 218, fill station 220, closing station222, sonic seal station 224 and top seal station 226. At the oppositeend of the machine, the robotic arms 228 move downwardly, grab thepouches and move them to a conveyor for loading into packaging. Thepouches then are rotated 180° to the start position and the receptaclesmay be washed as they move around to the start position.

The present invention has been described in an illustrative manner. Itis to be understood that the terminology which has been used is intendedto be in the nature of words of description rather than of limitation.

Many modifications and variations of the present invention are possiblein light of the above teachings. Therefore, within the scope of theappended claims, the present invention may be practiced other than asspecifically described.

1. A method of forming and filling a flexible pouch for packaging aproduct, said method comprising the steps of: forming a panel having anupper edge, a lower edge opposite the upper edge, and side edgesextending therebetween the upper and lower edges; joining two panels bysealing together the side edges and lower edge; opening the pouch;filling the pouch with the product; closing the filled pouch by forminga first closing seal extending along an upper edge of the pouch apredetermined length from the upper edge, such that there is no deadspace inside the pouch between the product and the first closing seal;forming a second seal between the first closing seal and the upper edge,wherein some of the product is trapped between the first closing sealand the second closing seal, to seal the upper edges of the panelstogether; and finishing the pouch.
 2. A method as set forth in claim 1,wherein the panel is formed from a laminate material including ametalized foil paper layer and a cast polypropylene layer.
 3. A methodas set forth in claim 1 wherein said step of joining the panel togetherfurther includes the steps of applying a first seal at low temperaturepositioned along the side edges and the lower edge of the panels andapplying a second seal at a higher temperature positioned adjacent thefirst seal and the product.
 4. A method as set forth in claim 1 whereinsaid step of joining the lower and side edges of the pouch togetherincludes the step of sealing the edges using a combination of heat andpressure.
 5. A method as set forth in claim 1 wherein said first closingseal is an ultrasonic weld.
 6. A method as set forth in claim 1 furthercomprising the step of inserting a fitment in the pouch panel fordispensing the product from the pouch.
 7. A method as set forth in claim6 wherein said fitment is a resealable, interlocking closing means.
 8. Amethod as set forth in claim 6 wherein said fitment is a screw-on cap.9. A method as set forth in claim 1 wherein said product is a carbonatedbeverage.
 10. A method of forming and filling a flexible pouch forpackaging a carbonated product, said method comprising the steps of:forming a panel having an upper edge, a lower edge opposite the upperedge, and side edges extending therebetween the upper and lower edges;joining two panels by sealing together the side edges and lower edge byapplying a first seal at low temperature along the side edges and loweredge and applying a second seal at a higher temperature adjacent thefirst low temperature seal and the product; opening the pouch; fillingthe pouch with the product; closing the filled pouch by forming a firstclosing seal extending along an upper edge of the pouch a predeterminedlength from the upper edge, such that there is no dead space inside thepouch between the product and the first closing seal; forming a secondseal between the first closing seal and the upper edge, wherein some ofthe product is trapped between the first closing seal and the secondclosing seal, to seal the upper edges of the panels together; andfinishing the pouch.
 11. A method as set forth in claim 10, wherein thepanel is formed from a laminate material including a metalized foilpaper layer and a cast polypropylene layer.
 12. A method as set forth inclaim 10 wherein said first closing seal is an ultrasonic weld.
 13. Amethod as set forth in claim 10 further comprising the step of insertinga fitment in the pouch for dispensing the product from the pouch.
 14. Amethod as set forth in claim 13 wherein said fitment is a resealable,interlocking closing means.
 15. A method as set forth in claim 10wherein said fitment is a screw-on cap.
 16. A method as set forth inclaim 10 wherein the first low temperature seal is at about 180° F. andthe second high temperature seal is at about 260° F.
 17. A method as setforth in claim 16 wherein the first low temperature seal has a greaterwidth than the second high temperature seal.